U.S. patent application number 09/842598 was filed with the patent office on 2002-12-05 for method for managing manufacturing data.
Invention is credited to Wright, Jason Richard.
Application Number | 20020183881 09/842598 |
Document ID | / |
Family ID | 25287753 |
Filed Date | 2002-12-05 |
United States Patent
Application |
20020183881 |
Kind Code |
A1 |
Wright, Jason Richard |
December 5, 2002 |
Method for managing manufacturing data
Abstract
A method for building a product tracking data history has steps
that include installing a remotely operable diagnostic tool on the
product which may be remotely operated during the product
manufacture process to report certain product specification data.
The method also has steps of placing product assembly
specifications and performance testing protocols on a central data
repository for remote access by the product assembler, thereby
reducing data transfer associated costs and efforts and eliminating
uncertainties regarding which assembly specifications and
performance test protocols are being used by an assembler.
Inventors: |
Wright, Jason Richard;
(Eagle, ID) |
Correspondence
Address: |
HEWLETT-PACKARD COMPANY
Intellectual Propery Adminitration
P.O. Box 272400
Fort Collins
CO
80527-2400
US
|
Family ID: |
25287753 |
Appl. No.: |
09/842598 |
Filed: |
April 25, 2001 |
Current U.S.
Class: |
700/115 ;
700/109 |
Current CPC
Class: |
G05B 2219/31286
20130101; G05B 2219/31283 20130101; G06Q 10/087 20130101; G05B
2219/31304 20130101; G05B 19/128 20130101 |
Class at
Publication: |
700/115 ;
700/109 |
International
Class: |
G06F 019/00 |
Claims
What is claimed is:
1. A method for building a product data tracking history of the
manufacture of a product of the type which has a processing means,
said method utilizing a central computer device operably connected
to a communications network, comprising the steps of: installing a
diagnostic tool on the product, said tool being of the type which
is capable of providing specification data about the product;
assigning a unique product identity code to the product; connecting
the product to the communications network; remotely operating said
diagnostic tool over the communications network from the central
computer device to provide said product specification data to the
central computer device, said product specification data comprising
at least said unique product identity code; and, building the
product tracking data history using said product specification data
with the central computer device.
2. A method as defined in claim 1 wherein said diagnostic tool
comprises at least computer executable instructions recorded on a
computer accessible medium.
3. A method for building a product tracking data history as defined
in claim 2 wherein said computer executable instructions comprise
at least instructions for determining an inventory of installed
components on the product, for storing and reporting said unique
product identity code, and wherein said product specification data
further comprises an inventory of components installed on the
product.
4. A method for building a product tracking data history as defined
in claim 1 wherein said step of building the product tracking data
history using said product specification data further comprises
assigning said unique product identity code to the product tracking
data history.
5. A method for building a product tracking data history as defined
in claim 1 wherein an operator computer device that at least
partially controls the manufacture of the product is connected to
the communications network, the method further comprising the steps
of: placing at least one set of product assembly specifications in
a central data depository connected to the central computer device;
assigning a unique identity code to each of said set of product
assembly specifications; transmitting said product assembly
specifications to the operator computer device for use in
assembling the product; and, wherein said product specification
data further comprises said unique identity code corresponding to
said product assembly specifications being transmitted to the
operator computer device.
6. A method for building a product tracking data history as defined
in claim 1 wherein the method further comprises the steps of:
providing at least one product performance test protocol; placing
said at least one product performance test protocol in a central
data repository connected to said central computer device; wherein
said step of remotely operating said diagnostic tool over the
communications network further comprises causing said diagnostic
tool to execute said at least one product performance test
protocol, and wherein said product specification data reported by
said diagnostic tool further comprises product performance test
results.
7. A method for building a product tracking data history as defined
in claim 6 wherein said method further comprises the step of:
assigning a unique test identity code to each of said at least a
product performance test protocol; and, wherein said product
specification data reported by said diagnostic tool further
comprises said unique test identity code corresponding to said
performance test protocol.
8. A method for building a product tracking data history as defined
in claim 7 wherein each of said at least a product performance test
protocol has a pass or fail outcome, and wherein the method further
comprises the step of: creating a product defect file in said
central data repository when a fail result occurs upon execution of
said at least a product performance test protocol.
9. A method for building a product data tracking history as defined
in claim 8 wherein said product defect file comprises at least said
test identity code for said product performance test protocol
resulting in said fail result.
10. A method for building a product tracking data history as
defined in claim 1 wherein the method is for manufacturing a
product for a product owner by at least an external contractor, the
at least an external contractor connected to the communications
network, and wherein the central computer device connected to said
network is under control of the product owner, wherein the method
further comprises the step of: connecting the product to the
communications network while the product is at the external
contractor; and, wherein said step of remotely operating said
diagnostic tool over the communications network comprises remotely
operating said diagnostic tool while the product is at the at least
an external contractor.
11. A method for building a product tracking data history as
defined in claim 10 wherein the method further comprises the step
of: assigning each of the at least an external contractor a unique
contractor code, and wherein said product specification data
further comprises said unique contractor code.
12. A method for building a product tracking history as defined in
claim 11 wherein the at least an external contractor comprises a
plurality of external contractors.
13. A method for building a product tracking data history for a
product manufactured for a product owner by at least an external
contractor, a communications network connecting the product owner
with each of the at least an external contractors, a central
computer device controlled by the product owner connected to the
communications network, the method comprising the steps of:
installing a diagnostic tool on the product, said diagnostic tool
being of the type which is capable of reporting specification data
about the product; assigning a unique product identity code to the
product; connecting the product to the communications network when
the product is at the at least an external contractor; remotely
operating said diagnostic tool over the communications network with
the central computer device to report product specification data to
a central data repository connected to the central computer device,
said product specification data comprising at least said unique
product identity code; and, building the product tracking data
history from said central data depository using said product
specification data.
14. A method as defined in claim 13 wherein said diagnostic tool
comprises at least computer executable instructions recorded on a
computer accessible medium.
15. A method for building a product tracking data history as
defined in claim 14 wherein said diagnostic tool recorded computer
executable instructions comprise at least instructions for
determining an inventory of installed components on the product,
means for storing said unique product identity code, and wherein
said product specification data further comprises an inventory of
components installed on the product.
16. A method for building a product tracking data history as
defined in claim 13 wherein said step of building the product
tracking data history from said central data depository using said
product specification data further comprises assigning said unique
product identity code to the product tracking data history.
17. A method for building a product tracking data history as
defined in claim 13, wherein the method further comprises the step
of: placing at least a set of product assembly specifications in
said central data repository whereby the at least an external
contractor may access said at least a set of product assembly
specifications remotely over the communications network to build
the product.
18. A method for building a product tracking data history as
defined in claim 17 wherein the at least an external contractor has
an operator computer device connected to the communications
network, and wherein the method further comprises the steps of:
assigning a unique product assembly specification code to each of
said at least a set of product assembly specifications;
transmitting said at least a set of product assembly specifications
over the communications network to the operator computer device;
and wherein said product specification data remotely reported over
the communications network from said diagnostic tool further
comprises said unique product assembly specification code
corresponding to said at least a set of product assembly
specifications transmitted to the operator computer device.
19. A method for building a product tracking data history as
defined in claim 13 wherein the method further comprises the steps
of: providing at least a product performance test protocol for
testing the performance of the product; and, placing said at least
a product performance test protocol in said central data repository
whereby said at least a product performance test protocol may be
transmitted over the communications network to the at least an
external contractor.
20. A method for building a product tracking data history as
defined in claim 19 wherein said step of remotely operating said
diagnostic tool over the communications network further comprises
causing said diagnostic tool to execute said product performance
test protocol, and wherein said product specification data reported
by said diagnostic tool further comprises results from execution of
said product performance test protocol.
21. A method for building a product tracking data history as
defined in claim 20 wherein the method further comprises the step
of assigning a unique test identity code to each of said at least a
product performance protocol, and wherein said product
specification data reported by said diagnostic tool further
comprises said unique test identity code corresponding to said
performance test protocol.
22. A method for building a product tracking data history as
defined in claim 21 wherein each of said at least a product
performance test protocol has a pass or fail outcome, and wherein
the method further comprises the step of creating a product defect
history file in said central data repository upon occurrence of
said fail result.
23. A method for building a product tracking history as defined in
claim 22 wherein said product defect history comprises at least
said product performance test identity code corresponding to said
product performance test resulting in said fail outcome.
24. A method for building a product tracking history as defined in
claim 13 wherein the at least a contractor comprises a plurality of
contractors; each of the plurality of contractors connected to the
communications network whereby each of the external contractors may
interface with said central data repository, and wherein the method
further comprises the step of: assigning each of the plurality of
external contractors a unique contractor code; wherein said step of
remotely operating said diagnostic tool over the communications
network further comprises connecting the product to the
communications network when the product is at each of the plurality
of contractors; prompting said diagnostic tool to provide said
unique contractor code corresponding to the contractor where the
product is; and, wherein said product specification data reported
over the communications network to said central data repository
further said unique contractor code.
25. A method for building a product tracking data history for a
product being manufactured for a product owner by at least an
external contractor, the product owner and at least an external
contractor connected to a communications network, the product owner
controlling a central computer device connected to the
communications network, each of the at least an external
contractors having an operator computer device connected to the
communications network for use in at least a portion of the product
manufacture, the method comprising the steps of: installing a
diagnostic tool on the product; said diagnostic tool being of the
type which is capable of providing specification data about the
product; said diagnostic tool comprising at least computer
executable instructions; assigning a unique product identity code
to the product, said unique product identity code accessible by
said diagnostic tool; assigning a unique contractor code to each of
the at least an external contractor; providing at least a set of
product assembly specifications; assigning each of said at least a
set of product assembly specifications a unique identity code;
placing said at least a set of product assembly specifications on
the central computer device; providing at least a product
performance test protocol; assigning each of said at least a
product performance test protocol a unique test identity code, each
of said at least a product performance test protocol having a pass
or fail outcome; placing said at least a product performance test
protocol on the central computer device; connecting the product to
the communications network when the product is at the at least an
external contractor; transmitting said at least a set of product
assembly specifications over the communications network to the
operator computer device at the external contractor when the
product is connected to said communications device; remotely
operating said diagnostic tool over the communications network to
report product specification data to the central computer device,
said product specification data comprising at least said unique
product identity code, an inventory of components installed on the
product, said unique product assembly code corresponding to said at
least a set of product assembly specifications transmitted over the
communications network, said unique contractor identity code
corresponding to the external contractor said set of product
assembly specifications are transmitted; remotely operating said
diagnostic tool to execute said at least a performance test
protocol to produce performance test results, remotely prompting
said diagnostic tool to report said performance test results over
the communications network to the central computer device; building
the product data history with the central computer device;
assigning said unique product identity code to the product data
history, the product data history comprising at least, said
inventory of components installed on the product, said unique
contractor code corresponding to the contractor the product is,
said product assembly specifications identity code corresponding to
said at least a set of product assembly specifications being
transmitted over the communications network to the operator
computer device, said performance test identity code for each of
said at least a performance test protocol executed by said
diagnostic tool with corresponding of said performance test
results; and, creating a product defect tracking history with the
central computer device upon a fail result after execution of any
of said at least a product performance test protocols, said product
defect history comprising at least said test identity code for said
at least a product performance test protocol resulting in said fail
result.
26. A method for creating a product tracking data history file as
defined in claim 25 wherein the at least an external contractor
comprises a plurality of external contractors.
27. A computer program product for causing a computer to create a
product tracking data history file for a product, the product
comprising processor means and having a unique product identity
code, the product having a diagnostic tool installed therein, the
diagnostic tool of the type capable of reporting product
specification data, the computer program product comprising a
computer usable medium having computer readable program code
embodied in the medium, the computer usable medium on a central
computer that is connected to a communications network, the
computer program product when executed causing the central computer
to: remotely operate said diagnostic tool over the communications
network when the product is connected to the communications network
to report product specification data to a central data repository
connected to the central computer device, said product
specification data comprising at least said unique product identity
code; and, build the product tracking data history from said
central data depository using said product specification data.
28. A computer program product as defined in claim 27, wherein at
least one set of product assembly specifications are stored in said
central data depository connected to the central computer device,
the product assembly specifications having a unique identity code,
and wherein the computer program product when executed causes the
central computer to: transmit said set of product assembly
specifications to an operator computer device connected to the
communications network, the operator computer device for use in at
least a portion of the manufacture of the product; and, wherein
said product specification data reported by said diagnostic tool
further comprises said unique identity code corresponding to said
product assembly specifications being transmitted to the operator
computer device.
29. A computer program product as defined in claim 27, wherein at
least one product performance test protocol is stored in said
central data depository connected to the central computer device,
each of said at least a performance test protocols having a unique
test identity code, and wherein the computer program product when
executed causes the central computer to: remotely operate said
diagnostic tool over the communications network to execute said at
least a product performance test protocol; and, wherein said
product specification data reported by said diagnostic tool further
comprises product performance test results and said unique test
identity code corresponding to said at least a product performance
test protocol being executed.
30. A computer program product for causing a computer to create a
product tracking data history file for a product, the product
comprising processor means and having a unique product identity
code, the product having a diagnostic tool installed thereon, the
diagnostic tool of the type capable of reporting product
specification data, the product being manufactured for a product
owner by an external contractor, a unique contractor code assigned
to the external contractor, the computer program product comprising
a computer usable medium having computer readable program code
embodied in the medium, the computer usable medium on a central
computer that is connected to a communications network, the product
connected to the communications network at the external
manufacturer, the computer program product when executed causing
the central computer to: transmit a set of product assembly
specifications stored on the central computer over the
communications network to an operator computer device at the
external contractor, the operator computer device for use in at
least a portion of the product manufacture, the set of product
assembly specifications having a specification identity code;
remotely operate the diagnostic tool over the communications
network to execute a product performance test protocol stored on
the central computer, said product performance test protocol having
a test identity code; remotely operate the diagnostic tool over the
communications network to report product specification data to the
central computer device; said product specification data comprising
at least the unique product identity code, the unique contractor
code, an inventory of components installed on the product, said
unique product specification code corresponding to said set of
product assembly specifications transmitted over the communications
network, performance test results resulting from executing said
product performance test protocol, said test identity code
corresponding to said product performance test protocol executed;
build the product data history; assign the unique product identity
code to the product data history, the product data history
comprising said inventory of components installed on the product,
the unique contractor code corresponding to the external contractor
the product, said product assembly specifications identity code
corresponding to said set of product assembly specifications being
transmitted over the communications network to said operator
computer device, said test identity code for said performance test
protocol executed by said diagnostic tool with corresponding of
said performance test results; and, create a product defect
tracking history with the central computer device upon a fail
result for any of said at least a product performance test
protocols, said product defect history comprising at least the
unique product identity code and said test identity code for said
at least a product performance test protocol resulting in said fail
result.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to methods for managing
manufacturing systems. In particular, the present invention relates
to methods for managing information flow along a manufacturing
supply chain regarding product specifications.
BACKGROUND OF THE INVENTION
[0002] In order to provide an acceptable level of quality for
commercial products, a product tracking data history for the
product needs to be built during the manufacture process.
Generally, this data history provides a list of which components
were installed in the product, when they were installed, and how
they were installed. The product tracking data history may further
include a history of performance tests done on the product as well
as any product defects that have been discovered.
[0003] Current manufacturing practices for large companies often
involve the manufacture of a product by a manufacturing group that
is far removed from the product designers. A plurality of component
parts may be obtained from outside vendors that are then assembled
to build the product. Under these circumstances it is difficult to
build an accurate product tracking data history due to the many
layers of organizational separation that exist within the company
between the product designer, or "owner", and the ultimate
assembler.
[0004] This problem is even more acute in so called "contract
manufacturing" situations, where a product is manufactured for a
product owner by an external contractor. These situations have
become popular in industry as they allow the product owner to focus
on product research, development, and marketing. As an example, a
computer peripheral manufacturer may research and design products,
and then contract out the manufacture of those products.
[0005] In both cases of internal manufacturing and contract
manufacturing, the process of manufacturing a product through
purchase of commodity component parts which are then assembled
together may generally be referred to as a "supply chain". In
essence, each of the various component vendors and the assemblers,
whether they are internal groups or external contractors, are a
link in the supply chain. The final assembly link of the chain is
critical, as it is here that the component parts are gathered
together and the product is put in a final form. Because the
product owner is removed from this final assembly link, the task of
building an accurate product tracking data history is
difficult.
[0006] At the final assembly link, the gathering of component parts
and product assembly may occur under a "manufacturing execution
system" ("MES"). The MES system generally coordinates product
assembly by listing component parts required, times when they are
required, places for the parts to be delivered, and specifications
for assembling the product. The removed product owner or designer
often depends completely on the contract assembler's MES to
implement the owner's specifications, and to provide data for
building a product tracking data history.
[0007] Relying on the assembly link MES in building a product
tracking data history, however, has proven less than satisfactory,
particularly for contract manufacturing situations. Generally,
relying on the assembly link MES requires the accurate transfer of
large amounts of data and know-how between the product owner and
the assembly MES. These tasks add effort and cost to the product
manufacture. Additionally, this is particularly difficult when the
MES is within an external contractor.
[0008] Under these circumstances, the product owner must rely on
the contractors to accurately transfer data. Errors may be
introduced when, for example, a contractor reports that a certain
product was built using a given specification or had particular
performance testing results when in fact this data is in error. The
possibility for these errors always exists when systems rely on
external organizations to install methods and systems, to gather
data, and to interpret and report data.
[0009] Partly in response to difficulties associated with relying
on external organizations for obtaining and reporting tracking
data, methods for building product data tracking histories have
been proposed in which the product owner provides automated testing
and documenting tools, often in the case of computer based tools.
Often these tools are installed onto the contractors computer based
MES system. In addition to providing assembly specifications, these
tools may be able to be run by the contractor to document product
components and to determine product performance. In theory they may
lower the burden placed on the contractors, and in turn may improve
accuracy of data transfer to the product owner.
[0010] In practice, however, such systems have proven less than
satisfactory. These computer based tools may require a considerable
degree of technical knowledge to install and operate, which
translates to costly information technology support for the
contractor. Additionally, assembly contractors and groups are
typically staffed with relatively low skill operators who are not
well suited for operating many of the computer based product
history tools. After turning the tool over to the contractor, the
product owner must rely on the contractor to insure that the tool
is installed and being used correctly. Further, the tools have done
little to alleviate the difficulties associated with transferring
large amounts of data between owner and contractor. Finally, use of
such computer based tools also introduces a new set of
administrative problems in that the tools must be continuously
updated and tracked to insure that each supply chain contractor is
running the latest version of a particular tool.
[0011] Additional problems exist in building product data tracking
histories related to detecting and resolving product defects. Even
if the reliability of the individual components has been assured,
they must still be properly installed to interface with one
another. This is particularly true of technically sophisticated
products such as computer peripherals. To insure proper interface,
product owners may require performance testing at the assembly
stage. The product owner provides specific testing protocols, which
may change during the product lifespan as components change.
[0012] Often the test protocols are provided in the form of
computer based tools, which the contractor must install and
maintain. These must be regularly updated and documented as the
protocols change. This again introduces technical support and
administrative problems for the contractor and the product owner
and adds cost to the manufacturing process. Additionally, in
contract manufacturing situations, the product owner must again
rely on an external organization to install, maintain, and
accurately document testing protocols and results.
[0013] When performance testing detects a defect, the product may
be sent to yet another contractor for defect resolution. This
second contractor will need access to the product tracking data
history to resolve the defect. The second contractor also needs to
know what sorts of performance tests were run, and what defects
those tests discovered. Providing all of this data to the second
contractor requires time and effort from the product owner, thereby
adding cost and delay to the manufacture process.
[0014] There are hence heretofore unresolved needs for methods for
building product tracking data histories as a product is
manufactured.
SUMMARY OF THE INVENTION
[0015] The present invention generally comprises an improved method
for building a product tracking data history for a product of the
type that has a processing means, with the method utilizing a
communications network with a central computer device attached
thereto. The method generally comprises the steps of installing a
remotely operable diagnostic tool on the product, assigning a
unique product identity code to the product, and connecting the
product to the communications network during its manufacture so
that the diagnostic tool may be remotely operated over the
communications network to provide product specification data. A
product tracking data history can then be built using the reported
product specification data.
[0016] Preferably, the diagnostic tool comprises at least computer
executable instructions recorded on a computer accessible medium,
such as an integrated circuit chip. The recorded instructions are
preferably capable of determining an inventory of components
installed on the product, and of providing the unique product
identity code.
[0017] In an additional embodiment of the improved method of the
invention, operator computer devices that are used for at least a
portion of the product manufacture are connected to the
communications network. This embodiment further comprises steps of
placing product assembly specifications on a central data
repository connected to the central computer, which are transmitted
from the central data repository to the operator computer devices
for use during the product manufacture. The diagnostic tool reports
back to the central computer device a unique identity code
corresponding to the assembly specifications being used to assemble
the product. This data is then included in the product tracking
data history, so that an accurate and automatically reported record
of what specifications were used to assemble the product is
created.
[0018] In still an additional embodiment of the invention, product
performance test protocols are placed on the central data
repository. When the product is connected to the communications
network during its manufacture, the diagnostic tool may be remotely
operated over the network from the central computer to execute the
test protocols and to report back to the central data repository an
identity code for the protocol test performed as well as test
results. This data is then included in the product tracking data
history. Upon a FAIL result for any performance test, a product
defect tracking history file may be created at the central data
repository.
[0019] This embodiment of the improved method of the invention
thereby results in accurate product testing without a requirement
for expensive operator training or action. Additionally, accurate
and automatically reported history of tests performed and test
results are thereby reported. Finally, upon the occurrence of a
test FAIL result, a centralized product defect history is started
that may be conveniently accessed during the defect resolution
process over the communications network by additional entities
along the supply chain.
[0020] In a most preferred embodiment of the method of the
invention, the product is being manufactured by at least an
external contractor for the product owner. In this embodiment of
the invention, the central computer device is under the control of
the product owner, and each of the external contractors is
connected to the communications network for interface with the
central computer device. It will be appreciated that practice of
this embodiment of the invention allows a product owner to keep
accurate and tight control over the external manufacture of the
product, as well as an accurate history of its manufacture.
[0021] All of the various embodiments of the method of building a
product tracking history briefly described above thereby resolve
several of the heretofore unresolved problems in the art. In
general, the various embodiments of the methods of the invention
advantageously remove layers of required interface and action in
the product tracking data transfer process between the product
owner and the product manufacturers. Depositing product assembly
specifications and product testing protocols at a central data
repository for remote access by contractors solves many problems
associated with the transfer of this data. Installing a self
diagnostic tool that is operated remotely over the communications
network solves many additional problems related to installing and
supporting systems at the contractor site for product testing. The
various embodiments of the method of the invention thereby offer a
greatly improved method for building a product data tracking
history.
[0022] The above brief description sets forth rather broadly the
more important features of the present disclosure so that the
detailed description that follows may be better understood, and so
that the present contributions to the art may be better
appreciated. There are, of course, additional features of the
disclosure that will be described hereinafter which will further
describe the subject matter of the invention. In this respect,
before explaining an embodiment of the disclosure in detail, it is
to be understood that the disclosure is not limited in its
application to the details of the construction and the arrangements
set forth in the following description or illustrated in the
drawings. The present invention is capable of other embodiments and
of being practiced and carried out in various ways, as will be
appreciated by those skilled in the art. Also, it is to be
understood that the phraseology and terminology employed herein are
for description and not limitation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is a schematic of a product owner and external
manufacturing contractors useful in describing practice of an
embodiment of the method of the invention.
[0024] FIGS. 2A-2B is a flowchart illustrating a set of steps of an
embodiment of the method of the invention.
DETAILED DESCRIPTION
[0025] The schematic of FIG. 1 will be helpful in describing a
preferred embodiment of the method of building a product data
tracking history of the invention. As discussed above, it has been
discovered that the method of the present invention is of
particular utility for the manufacture of technically sophisticated
products, such as computer peripherals. Accordingly, a preferred
embodiment will be described in reference to the hypothetical
production of a computer printer by Acme Co. 2 as shown in FIG. 1.
The schematic of FIG. 1 illustrates a contract manufacturing
situation, where Acme 2 has contracted out the manufacture of a
printer 4 to Contractor Alpha 6. It may be assumed that a plurality
of component parts have been obtained and shipped to Alpha 6, where
they will be assembled to create the final printer 4. Thus, Alpha 6
represents the final assembly "link" in the supply chain for
manufacturing the printer 4. Contractor Beta 8 has also been
contracted with for partial product manufacture; in particular Beta
8 will perform defect resolution tasks should a product defect be
detected.
[0026] This preferred embodiment of the method of the invention
will use a communications network 10. "Communications network" as
used herein is intended to refer to a means for achieving
communication between entities, and may include by way of example
and not limitation, wide area data networks, local area data
networks, virtual private data networks, a telephone network,
wireless networks, and the World Wide Web or Internet. Because of
its relative low cost and relative wide availability, the Internet
is a preferred communications network for the practice of this
embodiment of the invention method.
[0027] A central computer device 12 is under Acme 2 control. As
used herein, the term "under control" is intended to refer to a
general condition of being operably accessible and securable. That
is, a computer device may be considered to be "under the control"
of an entity if that entity may generally direct its operation and
may exclude others from using the computer device. Thus, for
instance, a computer device would be under the control of Acme it
is in Acme's facility and run by Acme's employees, if it is at a
computer operator facility that is contractually obligated to Acme
to operate the computer as Acme may direct, or the like.
[0028] Computer device 12 may comprise, by way of example and not
limitation, a processor based server device such as a personal
computer, workstation, or mainframe computer. The term "computer"
and "computer device" are thus intended herein to be read in their
broadest light, and generally are intended to refer to any machine
capable of processing instructions. Preferably, a central data
repository 14 is further provided and is connected to the central
computer device 12. The data repository 14 may comprise a storage
medium located in the central computer device 12, or may comprise a
remote storage medium such as an external disk drive, or even a
storage medium such as a disk drive residing in a second computer
device. The central computer device 12 is connected to the network
10.
[0029] As used herein, to "connect" an entity to the communications
network is intended to only refer to operably enabling
communications between the network and the entity. No particular
physical steps are required. In the schematic of FIG. 1, data
connections are illustrated with lines, which as will be
appreciated may represent phone lines, copper or fiber data lines,
wireless connections, or other means of data transfer.
[0030] The method of the invention may further comprise connecting
contractors Alpha 6 and Beta 8 to the network 10. Preferably, at
least one operator computer device 16 is provided at each
contractor Alpha 6 and Beta 8, with the operator computer device 16
of each respective contractor being connected to the network 10.
The operator computer device 16 is a processor based machine, and
may comprise by way of example a server device, a personal
computer, a workstation, or other processor based machine. The
operator device 16 is used to facilitate at least a portion of the
manufacture of printer 4. Operator computer device 16 will
facilitate connection to the printer 4 when it is present at the
particular contractor. In this manner, the printer 4 may be
connected to data the network 10 for communication with Acme 2. At
least one monitor 18 is preferably also provided at each of the
contractors Alpha 6 and Beta 8 connected to the operator computer
device 16.
[0031] It will be appreciated that a plurality of operator computer
devices 16 and monitors 18 may be comprised at Alpha 6 and Beta 8.
These computer devices 16 and monitors 18 may be networked together
in a LAN or WAN arrangement within one or more of the contractors.
Further, it will be appreciated that the preferred output device
comprising monitor 18 may further comprise means for inputting
data, such as virtual screen buttons or the like that may be used
by an operator to input data.
[0032] Each of the plurality of contractors Alpha 6 and Beta 8 can
communicate with the central computer device 12 and the data
repository 14 over the network 10. Likewise, the printer 4 may
communicate with the central computer device 12 and the data
repository 14 over the network 10 when connected to the operator
computer device 16 at any of the contractors 6 or 8.
[0033] The method of the invention further comprises the step of
assigning a unique product identity code to the printer 4. For
purposes of example, the printer 4 is assigned a code of "AZ467".
The code is preferably assigned to the printer 4 by physically
recording the product identity code on the printer 4 in a computer
readable format. It is noted that FIG. 1 as illustrated shows a
printer 4 at each of contractor Alpha 6 and Beta 8. It will be
appreciated that this is for purposes of illustration only, since
in practice there is only one unique printer 4 with identity code
AZ467.
[0034] Each of Acme 2, Alpha 6, and Beta 8 have a firewall 21
placed between them and the network 10. It will be appreciated that
such a configuration is advantageous for security reasons,
particularly when the communications network 10 is widely available
to other users, as of course is the case when the network 10
comprises the internet. As will be appreciated by those
knowledgeable in the art, the firewall 21 may take the form of
various devices or applications, and as used herein is intended to
refer broadly to a security application designed to selectively
allow communication therethrough.
[0035] The preferred embodiment of the method of the invention
further comprises the step of assigning a unique contractor code to
each of the plurality of contractors. For purposes of example
herein, the contractors 6 and 8 of FIG. 1 have been assigned codes
of "Alpha", and "Beta", respectively. It will be appreciated that a
wide variety of unique coding schemes for both contractors and
products can of course be comprised, the method of the invention
only requires that the codes be unique in that each contractor and
each individual product can be identified.
[0036] An additional step of the method of the invention is to
install a diagnostic tool on the printer 4. "Diagnostic tool" as
used herein is intended to refer to a tool that may be operated to
provide data regarding the product condition. Preferably, the
diagnostic tool comprises at least a set of recorded processor
executable instructions. A preferred example of a diagnostic tool
comprises a chip with computer executable instructions stored in
flash memory thereon for performing desired steps when queued.
Other examples may comprise computer executable instructions
recorded on other mediums. Thus, a diagnostic tool may comprise
recorded instructions on a magnetic or optical storage medium. For
purposes of illustration only, a diagnostic tool has been
illustrated as a black box 20 shown in the printer 4, which may be
considered to be a chip. Preferably, the diagnostic tool 20 has
recorded computer executable instructions thereon for providing the
printer's unique identity code, at least a partial inventory of
components installed on the printer 4, and for performing certain
performance tests.
[0037] In an additional step of the preferred embodiment of the
method of the invention, at least a set of product assembly
specifications is placed in the central data repository 14. The
term "a set of product assembly specifications" as used herein is
intended to refer to specifications regarding the construction,
design, or assembly of a product. For purposes of illustration,
sets of assembly specifications have been illustrated in FIG. 1 by
file 22 in the central repository 14. Each component to be
installed may require an individual set of assembly specifications
22. Alternatively, a single set of assembly specifications 22 may
provide instruction for multiple components to be installed by a
single or several contractors. For purposes of example and
convenience, it is put forth that a plurality of individual sets of
assembly specifications as will be required for assembly of the
printer 4 are present in the single file 22 of FIG. 1. Each
individual set of assembly specifications are additionally provided
with a unique identity code.
[0038] Under circumstances of contract manufacturing, product
performance tests will often be required of the contract assembler.
In the case of Alpha's 6 assembly of the printer 4, for example,
Acme 2 may require Alpha to conduct a performance test after each
component has been installed to insure that it is properly
installed and interfacing with other components properly.
Accordingly, a further step of the preferred embodiment of the
method of the invention is to place a set of performance test
protocols on the central data repository 14. "Product performance
test protocols", as used herein, are intended to refer broadly to
instructions for testing the performance of a product component.
Preferably, the instructions are computer readable and are
executable by diagnostic tool 20.
[0039] For purposes of illustration, a product performance test
protocol has been illustrated as the file 24 in the data repository
14 of FIG. 1. The performance test protocol file 24 may be
considered to contain a plurality of individual recorded
performance test protocols, each of which is assigned a unique
identity code in an additional step of the preferred embodiment of
the method of the invention.
[0040] Through still additional steps of the method of the
invention, diagnostic tool 20 will be remotely operated from the
central computer device 12 to provide various product tracking data
during the manufacture of the product 4 when connected to the
network 10. The diagnostic tool 20 will also be remotely operated
to execute performance tests, and to report results over the
network 10. These capabilities represent important advantages of
the method of the invention over methods of the prior art.
Generally, such a configuration advantageously removes dependence
on the supply chain contractors Alpha 6 and Beta 8 to accurately
transfer product-tracking data to Acme 2. Additionally, the burden
of installing, operating, and maintaining systems to obtain this
data is removed from contractors Alpha 6 and Beta 8.
[0041] In the preferred embodiment of the method of the invention,
when the printer 4 is connected to the communications network 10
while at Alpha 6 or Beta 8, three general types of data exchanges
occur over the network 10 with Acme 2: 1) the sets of assembly
specifications 22 are transmitted from the central repository 14
for the manufacture of the printer 4; 2) certain printer 4
diagnostic data is obtained through remote operation of the tool 20
and transferred to the data repository 14; and 3) the performance
test protocols 24 are transmitted from the repository 14 for
execution by the diagnostic tool 20 with test results then
transferred directly back from the diagnostic tool 20 to the
repository 14. A comprehensive product data tracking history can
then be assembled by the central computer device 12 using these
three general types of data.
[0042] To further illustrate the preferred embodiment of the method
of the invention, a product-tracking data history will be assembled
for the printer 4 of FIG. 1 with unique product identity code
AZ467. The sample product tracking data history that results from
practice of this embodiment of the method of the invention is
illustrated in Table 1. It will be appreciated that this product
tracking data history is presented for illustration only, and is
not intended to express any limitations regarding product data
tracking histories built through the method of the invention as
claimed, which may contain more or less data than that illustrated
and which may be in different formats. The steps of the method
taken to build this history will be discussed in detail below.
1TABLE 1 Example Product Tracking History Product Tracking Data
History for Product Code: AZ467 Components: Product Performance
Tests: Assembly Dates Specifications Used at Performance Test
Protocol Date Test Printer at Components installed Date Contractor
to install with Results for Tests at Run at Contractor: Contractor:
at Contractor: Installed: Component: Contractor: Contractor: Alpha
9/3/00- Board 11 9/4 Board Rev. 1 Board Test Rev. 2: PASS 9/4
10/11/00 Motor 14C 9/4 Motor Rev. 1 Motor Test Rev. 1: PASS 9/4 Bus
9/6 Bus Rev. 2 Bus Test Rev. 1: PASS 9/6 LCD Screen JX3 9/20 Screen
Rev. 1(b) Screen Test Rev. 1(b): PASS 9/21 Printer Drive Head Z
10/3 PH Rev. 3 PH Rev. 2: PASS 10/4 Disk Drive SD3 10/5 Disk Drive
Rev. 1 Disk Drive Rev. 2: FAIL 10/5 Beta 10/19/00- Disk Drive SD3
10/25 Disk Drive Rev. 1 Disk Drive Rev. 2: PASS 10/25 10/26/00
Board Test Rev. 2: PASS 10/25
[0043] In order to better illustrate the preferred embodiment of
the method of the invention, the steps of the method will be
discussed in detail from the point at which the printer 4 with
diagnostic tool 20 installed thereon is connected to the operator
computer device 16 at Alpha 2 of FIG. 1. It will be appreciated
that by the time this occurs, a number of component parts have been
obtained, gathered together, and delivered to an operator for
assembly.
[0044] Reference is now drawn simultaneously to FIG. 1 as well as
FIGS. 2A-2B, which are a flow chart illustrating the preferred set
of method steps that occur once the operator at Alpha 2 has been
delivered all component parts for the printer 4 and is ready to
begin assembly. At this point (100), a set of product assembly
specifications 22 are transmitted over the network 10 for output on
the Alpha operator output device 18. Preferably, as illustrated,
the output device 18 comprises a monitor on which the operator will
view assembly specifications on a step by step basis. Other output
devices may comprise printers or other devices.
[0045] The Alpha operator then assembles the printer 4 following
the assembly specifications 22 (102). Assembly specifications may
comprise descriptions of parts to be installed, as well as
instructions for installation. They may be presented in a
step-by-step manner, with the operator required to interact with
the output device 18, such as, by way of example, clicking a mouse
button or striking a "virtual" button on the output device 18 after
each step to begin the next step. Additionally, assembly may occur
on an assembly line between a number of different operators. In
this case the method of the invention will comprise providing a
plurality of the output devices 18, with one for each operator
station.
[0046] Importantly, through the method of the invention the actual
file 22 containing these assembly specifications remains under
Acme's control on the central data repository 14. This allows Acme
to retain tight and accurate control over the assembly
specifications actually being used during product manufacture by
the various contractors. Any changes to assembly specifications
that need to be made can be easily accomplished without requiring
any actions on the part of the contractors. The method of the
invention thereby completely removes any uncertainty as to which
version of assembly specifications are being used by the
contractor. Further, burdens on contractors such as Alpha
associated with installing, maintaining, and updating assembly
specifications are eliminated.
[0047] The preferred embodiment of the invention further comprises
storing previous versions of assembly specifications in the central
data repository 14 as newer versions are installed. This
advantageously creates an archive for future reference that can be
widely accessed over the network 10.
[0048] As indicated by the sample product data tracking history of
Table 1, the printer 4 is assembled using individual assembly
specification sets for a board, a motor, a bus, an LCD screen, a
printer drive head, and a disk drive. Again referring to FIGS. 1
and 2, the operator prompts the output device 18 that assembly of
the printer 4 is completed (104). The operator is then prompted to
connect product 4 to the operator computer device 16 (106).
Connection may occur, by way of example, by the operator connecting
a pin connector on a cable to a serial port connection, or by
initiating a wireless connection with the product 4. Other modes of
connection are of course within the scope of the invention as will
be appreciated by those knowledgeable in the art.
[0049] The diagnostic tool 20 is then remotely operated over the
network 10 from the central computer device 12 (108) to provide
product specification data (110). As indicated, this specification
data preferably comprises at least the product unique identity code
AZ467, an inventory of installed components, and a list of assembly
specification set identity codes used to install the various
components in the product. Table 1 indicates that installed
components are identified by a model number. It is within the scope
of the invention to also identify installed components by serial
number or other identifying data.
[0050] It is also noted that not all components need be listed.
Indeed, the preferred embodiment of the method of the invention
will provide an inventory only of relatively "high touch"
electronic components that are important to the product operation.
Things such as housings and simple mechanical parts without
electronic interface may not be practical to inventory or test with
the diagnostic tool 20.
[0051] It is further noted that the scope of the invention as
claimed is not limited to this specification data being provided
only from the diagnostic tool 20, but may for example also be
obtained by combining some data provided by the tool 20 with data
obtained by the central computer device 12. For instance, after
learning the identity code of product 4 and inventory of installed
components from the tool 20, the central computer 12 may query the
data repository 14 to obtain identity codes for the current
assembly specifications corresponding to the installed
components.
[0052] Product performance testing of product 4 may then be
initiated (110). This involves transmission of product performance
test protocols in file 24 over the network 10 for execution by
diagnostic tool 20. As indicated by the sample product tracking
data history of Table 1, performance test protocols may be run on
each individual component. Preferably, the performance test
protocols when executed by diagnostic tool 20 will at least
indicate whether the component being tested is interfacing properly
with other components. Test protocols preferably have a PASS/FAIL
outcome. In addition to having an individual performance test
protocol for each component, performance test protocols may be
executed that measure performance of a plurality of components in a
single test. A test protocol may even be executed for measuring the
overall product performance.
[0053] The method of the invention thereby achieves several
advantageous results in product performance testing over methods of
the prior art. Because test protocols are retained under the
product owner's control, any uncertainty as to which test protocol
is being run has been removed, and any changes that need to be made
in terms of installing new revisions of test protocols can be very
quickly accomplished. Further, remote operation of the diagnostic
tool 20 from the central computer device 12 to execute performance
test protocols removes the burden of installing, maintaining, and
performing tests from contractors such as Alpha.
[0054] Product performance test protocols may provide an interface
screen on the central computer device 12 for an Acme operator to
participate in executing the test. As an example, an interface
screen may display test results dynamically, with the Acme operator
able to remotely direct the diagnostic tool 20 to take any of
several actions as may be desired depending on the dynamically
displayed test results. By way of additional example, execution of
test protocols may request other operator interaction. With
reference to Table 1, the LCD screen installed on the printer 4 is
to be performance tested under test protocol Screen Test Rev. 1(b).
This test protocol may direct the diagnostic tool 20 to test a
connection between the main board and the screen, and then to test
the screen operation by displaying certain characters on the
screen. The test protocol may further direct that the operator is
to interact with the operator output device 18 by clicking a mouse,
pressing a virtual screen button, or in some other manner to
confirm that the characters are displayed on the screen. Other test
protocols by way of example may direct the Alpha operator to turn
printer switches on and off or to take other actions on the
printer.
[0055] The central computer 12 directs the diagnostic tool 20 to
transmit PAS S/FAIL results for performance testing to the central
computer device 12, along with the test identity code for the test
protocol executed (112). In addition to PASS/FAIL results,
performance tests may have other outcomes indicative of component
performance such as numerical values. It will also be appreciated
that PASS/FAIL results may comprise numerical values, as for
instance if a value below a certain numerical limit is assigned a
FAIL result.
[0056] As discussed herein above, during a product lifetime it is
likely that the product will change. As these changes occur it is
likely that performance testing protocols will likewise change. It
is an important advantage of the method of the invention that the
product tracking data history being built includes a record of
which test protocol was run; hence the test identity code is
recorded. It is likewise an important advantage of the method of
the invention that new protocols may be easily installed on the
central repository 14. This eliminates any uncertainty as to which
test protocol is being run by the contractor, and also eliminates
burdens associated with installing and training contractors such as
Alpha operators to run the tests. Additionally, the preferred
embodiment of the invention further comprises storing previous test
protocol versions on the central repository 14 for future
reference.
[0057] It is noted that although FIG. 2A indicates that the
diagnostic tool will transmit the test identity code (112), this
information may likewise be determined by the central computer
device 12 within the scope of the present invention. By way of
example, the diagnostic tool 20 may be prompted to transmit
performance test results, with the central computer 12 then
querying the central repository 14 for the current test identity
codes corresponding to the test protocols being executed.
[0058] The product tracking data history is finally built (114),
and is summarized in FIG. 2B (116). Generally, a preferred product
tracking data history as summarized in FIG. 2B (116) is
representative of the sample product tracking data history of Table
1. The unique printer identity code AZ467 is first associated with
the tracking data history; in this manner there will be one
individual tracking history for each individual product. Product
specification data as well as performance test results are then
placed in the file. As indicated this data generally comprises an
inventory of components installed, assembly specifications used to
install the components, dates installed, performance test results
for the components, identity of performance test protocols run, and
dates the performance tests were run.
[0059] The actual product tracking data history created is
preferably in computer readable format, and is placed in the data
repository 14 of FIG. 1. The product tracking data history has been
indicated as file 26 in FIG. 1. In a most preferred format the file
is in a widely readable database or spreadsheet format, with
examples including but not limited to Microsoft Excel or Lotus
1-2-3. This advantageously makes it widely available.
[0060] FIG. 2B also indicates that a second Product Defect History
file may be created if any performance test had a fail result
(118). As an example, it is noted from Table 1 that the printer 4
had a FAIL result for "Disk Drive Rev. 2" performance test. This
FAIL flag when processed (118) results in creation of a product
defect history file (120). If no FAIL results were obtained, no
action is taken (119). This product defect history file generally
comprises a history of tests run on the components and test
results. The product defect history file will be placed on the
central repository 14, as indicated by file 30 in FIG. 1.
[0061] In practice, when a product is determined to have a defect,
it may be directed to a second contractor or group for defect
resolution. In the hypothetical printer manufacture process as
presented by FIG. 1, upon detection of the disk drive failure, the
printer 4 is sent to defect resolution contractor Beta 8 for
repair. Once at Beta 8, the printer 4 is connected to the Beta
operator device 16, which in turn allows the printer 4 to
communicate with the central computer device 12 over the network
10. After transmitting the printer 4 unique identity code AZ467 to
the central computer device 12, the Beta operator may obtain access
to both the product defect history file 30 and the product tracking
data file 26 for output on the operator output monitor 18.
[0062] With this valuable information the Beta operator may attend
to quickly resolving the disk drive defect in the printer 4. The
Beta operator is not required to obtain paper histories of the
printer 4 manufacture or testing from Alpha 6 or Acme 2, or to have
personal interface with Alpha 6 or Acme 2 as was required for
methods of the prior art. This greatly speeds and reduces the cost
of the defect resolution process.
[0063] Any changes made to the printer 4 by Beta 8 in resolving the
defect may further be recorded remotely over the communications
network 10 in the product data tracking history 26 and in the
product defect history file 30. Additionally, at the completion of
defect resolution at Beta 8, performance testing of the disk drive
as well as additional components as may be required using the
performance test protocol set 24, with results also recorded in the
product tracking data history, as indicated in the sample product
tracking data history of Table 1.
[0064] It will be appreciated that many variations on the preferred
embodiment of the method of the invention as described herein are
within the scope of the claims appended hereto. As an example,
additional contractors may be comprised in addition to those
illustrated in FIG. 1 and discussed herein. A second assembly
contractor, in addition to Alpha 6, for instance, could be used to
install an additional group of components on the printer 4.
[0065] Further, it will be appreciated that the method of the
invention is not limited to a contract manufacture situation, but
likewise may be applied to purely internal manufacture. In this
sense it would be applicable to describe the product owner Acme in
FIG. 1 to comprise a design group, and contractor Alpha to comprise
an Acme manufacturing group that may be located in the same
location as the product owner group and that is connected to the
product owner group via a LAN. The assembly group could of course
likewise be remotely located.
[0066] It will further be appreciated that the group of method
steps as described in the flow chart of FIGS. 2A-2B should not be
considered to limit the sequence of steps described therein. It
will be apparent that the steps described could be carried out in a
different sequence to accomplish the same result. For example,
nodes 108 and 110 could easily be reversed in sequence without
changing any method results. As an additional example, the printer
4 could be connected to an operator computer device 16 at an
earlier step in the flow chart so that the printer 4 is "on-line"
throughout assembly.
[0067] Additionally, it will be appreciated that the method of the
invention as claimed will be equally applicable to automated
manufacturing that does not require human operators. As an example,
the operator computer device 16 at Alpha 6 could comprise or
control a robotic device that assembles the printer 4. Further,
sets of assembly specifications could comprise executable
instruction for the robotic devices.
[0068] It will further be appreciated that the method of the
invention is well suited to performance by a computer, and may in
fact comprise the steps of the invention as described herein in the
form of a set of computer instructions contained in a computer
accessible medium such as a magnetic or optical storage media for
causing a computer to perform the various steps of the method of
the invention.
[0069] In particular, the present invention may comprise a computer
program product for causing the central computer 12 of FIG. 1 to
create a product tracking data history file for printer 4 by
executing instructions that cause the central computer 12 to
interface with the diagnostic tool 20 and with operator device 16
over the data network 10 to perform the various steps of the method
of the invention as described herein.
[0070] The various steps of the method of the invention as detailed
herein with reference to a preferred embodiment thereby provide a
novel and efficient method for building a comprehensive product
tracking data history for a product as it is manufactured by a
plurality of contractors. As summarized in the hypothetical product
tracking history of Table 1, the history provides a detailed
history of what was installed in the product by whom, when it was
installed, and under what specifications. Additionally, a history
of what protocols were used to test each component, when it was
conducted, and what results were obtained is likewise recorded.
Importantly, this comprehensive product tracking data history is
able to be built through the novel method of the invention with
much greater accuracy and with much less cost and effort than was
possible using methods of the prior art.
[0071] The advantages of the disclosed invention are thus attained
in an economical, practical, and facile manner. While preferred
embodiments and example configurations have been shown and
described, it is to be understood that various further
modifications and additional configurations will be apparent to
those skilled in the art. It is intended that the specific
embodiments and configurations herein disclosed are illustrative of
the preferred and best modes for practicing the invention, and
should not be interpreted as limitations on the scope of the
invention as defined by the appended claims.
[0072] Various features of the invention are set forth in the
appended claims.
* * * * *